Over the past few decades, various control domains such as process control, batch control, motion control, and discrete control have been consolidated into a unified automation architecture. This integration has reduced disparate systems and interfaces within process operations, making work significantly easier. However, one technology that historically resisted assimilation into this common automation architecture was the Safety Instrumented System (SIS) – at least until recently.
With the advent of integrated SIS, this critical process safety system can now reside on the same platform as the Basic Process Control System (BPCS). Today, both systems can be programmed, configured, operated, and maintained together, forming a truly unified automation architecture.
Streamlining Device Configuration and Deployment
Safety standards within the process industries have historically mandated that safety systems operate separately from process control platforms. However, this trend is shifting, and fully integrated systems capable of handling both BPCS and SIS are now permissible. This integration optimizes workflows for engineers, who now only need to learn and understand a single platform to manage both the BPCS and safety systems. Whether building process loops or safety loops, the operational mechanisms are the same. Furthermore, because the software environment is common to both SIS and BPCS, configuration and programming tasks become simpler and can be completed more quickly.
Integrated SIS also optimizes and accelerates the commissioning process. With a common architecture, teams become smaller and more efficient, eliminating the need for multiple engineers with specialized knowledge in both BCPS and SIS platforms.
Simplifying Field Operations
For field operations teams, the unified platform for BPCS and SIS offers similar simplifications. Production and maintenance personnel now only need to learn one hardware and software system to operate, monitor, and maintain both systems. Inventory can also be optimized, and costs reduced, as maintenance teams only need to stock spare parts for one platform rather than two. Simultaneously, if maintenance teams require vendor support, they only need to contact a single service provider for issues related to both BPCS and SIS.
Integrated SIS can also bring modern functionalities to field teams that were not available with traditional SIS. For example, new integrated SIS solutions offer redundant system updates. This means that SIS controllers, communication modules, and redundancy modules can be updated while the system is running, eliminating the need to schedule updates during planned shutdowns.
Accessing Diverse Data Sources
Consolidating disparate systems into a unified architecture also means consolidating diverse data sources. This enables process operators to combine and contextualize a wider variety of data, creating a more comprehensive operational view. At a minimum, centralizing BPCS and SIS data onto a single platform makes it easier for operators to understand what is happening in their production.
Historically, creating a unified Human-Machine Interface (HMI) display was difficult because BPCS and SIS used different logics. Now, with BPCS and SIS data originating from the same platform and utilizing the same logic, building a unified HMI view becomes much simpler and more intuitive.
Combining BPCS and SIS data also provides new insights for field personnel. For example, it can provide a visualization of how close the process is to the setpoint that would trigger the SIS to take over, helping personnel to proactively monitor and address issues before they lead to a shutdown.
While integrated SIS offerings are still a relatively emerging area in the market, they have been successfully deployed in a variety of applications, including general process safety applications and hybrid applications requiring the simultaneous consideration of both machine safety and process safety. As the application scenarios for integrated SIS continue to expand, more and more process operators will be able to finally move away from treating SIS as an isolated system within their operations, leading to simpler device deployment and improved plant uptime and safety.
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